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Ok so currently I am planning to use marine board for my formers it is far lighter, does not rot, and is fire resistant compared to inexpensive plywood on the market. The cabin I plan to use Aluminum Honeycomb as it is extremely light and strong. Limiting the aluminum honeycomb to only the cabin will help keep the costs down a bit yet still create an extremely strong and safe vehicle cabin.
Once I have built the formers and constructed the cabin I will shape the body out of polyurethane 2lb density board stock. The majority of the composite material will be fiberglass. However one could also use carbon fiber and kevlar as a substitute but costs will be much more. I may use a CF/Kevlar hybrid material in the floor boards and around other key reinforcement areas of the cabin for added strength and safety. The majority of the composite will be out of fiberglass to keep costs down and to use for the prototype body kit. This way if I need to make changes I can do so without crying cuz I just destroyed an expensive piece of Carbon fiber or Kevlar composite piece lol :-)
The plan is to use 2 layups of 5.7 oz fiberglass in all areas other than around the cabin and in key joints that need added strength. In these areas I will utilize an additional 2 layups at least 4" wide. This material like I said may be CF/Kevlar composite rather than fiberglass for the additional strength and safety factor. The material I would prefer to orient in a weave configuration running across each other. I think I will most likely go with a satin weave vs a plain weave.
I hope this gives you a little better idea of how I plan to create the cabin and body shell. This will not be a quick process at all but hopefully when I am finished it will be something that will be of great satisfaction and something others can gain some kind of insight into and or advantage if they would like there own.
Feel free to ask me any other questions you have. Take car and have a nice week :-)
GH..
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